U.S. patent application number 16/087185 was filed with the patent office on 2019-03-28 for leak sensor assemblies and systems utilizing same.
This patent application is currently assigned to Molex, LLC. The applicant listed for this patent is Molex, LLC. Invention is credited to Alexander S. CHERNYSHOV, Reichl B. HASKELL, David R. MASSNER, Wenfeng PENG, Dumitru ROSCA, Marko SPIEGEL.
Application Number | 20190094101 16/087185 |
Document ID | / |
Family ID | 59900793 |
Filed Date | 2019-03-28 |
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United States Patent
Application |
20190094101 |
Kind Code |
A1 |
SPIEGEL; Marko ; et
al. |
March 28, 2019 |
LEAK SENSOR ASSEMBLIES AND SYSTEMS UTILIZING SAME
Abstract
The present disclosure provides a leak sensor assembly which is
configured to detect the leakage of gas from a component of a
piping system. The leak sensor assembly includes a housing and at
least one sensor. The housing is configured to be positioned
proximate to the component and forms a pocket which allows gas
leaked from the component to concentrate within the pocket in a
generally uniform dispersion. The at lease one sensor is configured
to detect the presence and concentration of gas within the pocket
of the housing.
Inventors: |
SPIEGEL; Marko; (LaFox,
IL) ; CHERNYSHOV; Alexander S.; (Naperville, IL)
; PENG; Wenfeng; (North Aurora, IL) ; HASKELL;
Reichl B.; (Glen Ellyn, IL) ; MASSNER; David R.;
(Joliet, IL) ; ROSCA; Dumitru; (Lisle,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Molex, LLC |
Lisle |
IL |
US |
|
|
Assignee: |
Molex, LLC
Lisle
IL
|
Family ID: |
59900793 |
Appl. No.: |
16/087185 |
Filed: |
March 20, 2017 |
PCT Filed: |
March 20, 2017 |
PCT NO: |
PCT/US2017/023213 |
371 Date: |
September 21, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62311093 |
Mar 21, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01N 33/0047 20130101;
G01M 3/36 20130101; G01M 3/28 20130101; G01M 3/2876 20130101; G01M
3/2853 20130101 |
International
Class: |
G01M 3/28 20060101
G01M003/28 |
Claims
1. A leak sensor assembly, the leak sensor assembly configured to
detect the leakage of gas from a component of a piping system, the
leak sensor assembly comprising: a housing defining a pocket, at
least two component receiving openings which are configured to
receive components of the piping system, a sensor opening, and one
or more drain openings configured to provide an exit for leaked gas
and/or moisture that has built-up within the pocket, the sensor
opening being separated from the at least two component receiving
openings, the one or more drain openings being separated from the
at least two component receiving openings and the sensor opening,
the housing being configured to be positioned proximate to the
component, wherein gas leaked from the component concentrates
within the pocket in a generally uniform dispersion; and at least
one sensor mounted on the housing in the sensor opening, the at
least one sensor configured to detect the presence and
concentration of gas within the pocket of the housing.
2. The leak sensor assembly as defined in claim 1, wherein the one
or more drain openings are provided at a lower portion of the
housing.
3. The leak sensor assembly as defined in claim 1, wherein the
housing is formed of a microporous material and the one or more
drain openings are provided by one or more microscopic openings in
the microporous material.
4. The leak sensor assembly as defined in claim 1, wherein the
housing has an inner wall surface and an outer wall surface, the
inner wall surface is generally conical.
5. (canceled)
6. The leak sensor assembly as defined in claim 1, wherein the
housing is formed of a single part which can be opened or closed
around the piping system.
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. The leak sensor assembly as defined in claim 1, wherein the
housing further comprises a collar forming the sensor opening, the
collar having an attachment thereon, and the sensor comprises a
body having an attachment thereon, wherein the attachment on the
collar is releasably engaged with the attachment on the sensor.
12. (canceled)
13. The leak sensor assembly as defined in claim 1, wherein the
housing is formed of two halves which are mated together around the
piping system, and are attached to each other by a securing
mechanism.
14. (canceled)
15. (canceled)
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. (canceled)
21. (canceled)
22. (canceled)
23. (canceled)
24. (canceled)
25. (canceled)
26. (canceled)
27. (canceled)
28. (canceled)
29. The leak sensor assembly as defined in claim 1, wherein the at
least one component receiving openings closely conform in shape to
the components of the piping system.
30. The leak sensor assembly as defined in claim 1, further
comprising a pump which is configured to draw leaked gas within the
pocket toward the at least one sensor.
31. The leak sensor assembly as defined in claim 1, further
comprising a fan which is configured to blow leaked gas within the
pocket toward the at least one sensor.
32. (canceled)
33. (canceled)
34. (canceled)
35. (canceled)
36. (canceled)
37. (canceled)
38. The leak sensor assembly as defined in claim 1, wherein a
hydrophobic/gas permeable filler is provided in the pocket.
39. (canceled)
40. A leak sensor assembly, the leak sensor assembly configured to
detect the leakage of gas from a component of a piping system, the
leak sensor assembly comprising: a housing defining a pocket, at
least two component receiving openings which are configured to
receive components of the piping system and a sensor opening, the
housing being configured to be positioned proximate to the
component, wherein gas leaked from the component concentrates
within the pocket in a generally uniform dispersion, the housing
having a first part of an interengaging assembly thereon; a sensor
releasably mounted to the housing in the sensor opening, the sensor
comprising a body having a second part of the interengaging
assembly thereon, the sensor configured to detect the presence and
concentration of gas within the pocket of the housing; and wherein
the first part is releasably engaged with the second part.
41. The leak sensor assembly as defined in claim 40, wherein one of
the first part and the second part comprises at least a pair of
ears and the other of the first part and the second part comprises
at least a pair of passageways into which the ears are
received.
42. (canceled)
43. The leak sensor assembly as defined in claim 40, wherein the
housing has a wall and an inner collar attached to the wall, which
inner collar further defines the pocket, and the sensor opening is
formed by an outer collar attached to the wall, wherein the wall is
secured between the inner and outer collars.
44. The leak sensor assembly as defined in claim 43, wherein the
inner and outer collars are attached to each other.
45. (canceled)
46. (canceled)
47. (canceled)
48. (canceled)
49. (canceled)
50. A leak sensor assembly, the leak sensor assembly configured to
detect the leakage of gas from a component of a piping system, the
leak sensor assembly comprising: a housing having a rigid wall and
a securement provided on the wall, the securement is configured to
releasably attach the wall to the piping system, the wall defining
a pocket, at least two component receiving openings which are
configured to receive components of the piping system and a sensor
opening in communication with the pocket, the wall being configured
to be positioned proximate to the component via the securement,
wherein gas leaked from the component concentrates within the
pocket in a generally uniform dispersion; and at least one sensor
mounted on the wall in the sensor opening, the at least one sensor
configured to detect the presence and concentration of gas within
the pocket of the housing.
51. The leak sensor assembly as defined in claim 50, wherein the
wall has a first part of an interengaging assembly thereon and the
sensor comprises a body having a second part of the interengaging
assembly thereon, wherein the first part is releasably engaged with
the second part.
52. The leak sensor assembly as defined in claim 51, wherein one of
the first part and the second part comprises at least a pair of
ears and the other of the first part and the second part comprises
at least a pair of passageways into which the ears are
received.
53. The leak sensor assembly as defined in claim 50, further
comprising a second housing attached to the first housing.
54. (canceled)
55. (canceled)
56. The leak sensor assembly as defined in claim 53, wherein the
second housing is attached to the wall.
57. The leak sensor assembly as defined in claim 50, wherein the
securement comprises a plurality of magnets mounted on the wall,
the magnets being configured for magnetic attachment to the
component.
58. The leak sensor assembly as defined in claim 50, wherein the
securement comprises a strap attached to the wall, the strap being
configured for attachment to the component.
59. (canceled)
60. A leak sensor assembly, the leak sensor assembly configured to
detect the leakage of gas from a component of a piping system, the
leak sensor assembly comprising: a housing having a first end, a
second opposite end, an inner wall surface extending from the first
end to the second end, an outer wall surface extending from the
first end to the second end, the housing defining at least two
component receiving openings which are configured to receive
components of the piping system and a sensor opening extending from
the inner wall surface to the outer wall surface, wherein the inner
wall surface is generally conical from the first end to the second
end and defining a generally conical pocket, the housing being
configured to be positioned proximate to the component, wherein gas
leaked from the component concentrates within the pocket in a
generally uniform dispersion; and at least one sensor mounted on
the housing in the sensor opening, the at least one sensor
configured to detect the presence and concentration of gas within
the pocket of the housing.
61. (canceled)
62. (canceled)
63. (canceled)
Description
RELATED APPLICATIONS
[0001] This application claims the domestic of U.S. Ser. No.
62/311,093, filed on Mar. 21, 2016, the contents of which are
incorporated herein in its entirety.
TECHNICAL FIELD
[0002] This disclosure relates to the field of sensors, more
specifically to the field of leak sensor assemblies and systems
utilizing same.
DESCRIPTION OF RELATED ART
[0003] Process plants, such as petroleum refineries and chemical
manufacturing facilities, have many complex issues associated with
gas leaks. In October 2007, the United States Environmental
Protection Agency ("EPA") issued a document entitled "Leak
Detection and Repair--A Best Practices Guide". According to this
document, the EPA has determined that leaking equipment, such as
valves, pumps, and connectors, are the largest source of emissions
of gases, such as volatile organic compounds ("VOCs") and volatile
hazardous air pollutants ("VHAPs"), from petroleum refineries and
chemical manufacturing facilities.
[0004] VOCs contribute to the formation of ground-level ozone.
Ozone is a major component of smog, and may cause or aggravate
respiratory disease. Many areas of the United States, particularly
those areas where refineries and chemical facilities are located,
do not meet the National Ambient Air Quality Standard ("NAAQS") for
ozone.
[0005] Some species of VOCs are also classified as VHAPs. Some
known or suspected effects of exposure to VHAPs include cancer,
reproductive effects, and birth defects. The highest concentrations
of VHAPs tend to be closest to the emission source, where the
highest public exposure levels are also often detected. Some common
VHAPs emitted from refineries and chemical plants include
acetaldehyde, benzene, formaldehyde, methylene chloride,
naphthalene, toluene, and xylene.
[0006] A typical refinery or chemical plant can emit hundreds of
tons per year of VOCs from leaking equipment, such as valves,
connectors, pumps, sampling connections, compressors,
pressure-relief devices, and open-ended lines.
[0007] Valves are used to either restrict or allow the movement of
fluids. Valves come in numerous varieties and, except for
connectors, are the most common piece of process equipment in
industry. Leaks from valves usually occur at the stem or gland area
of the valve body and are commonly caused by failure of the valve
packing or O-ring.
[0008] Connectors are components such as flanges and fittings used
to join piping and process equipment together. Gaskets and blinds
are usually installed between flanges. Leaks from connectors are
commonly caused from gasket failures and improperly torqued bolts
on flanges.
[0009] Pumps are used to move fluids from one point to another. Two
types of pumps extensively used in petroleum refineries and
chemical plants are centrifugal pumps and positive displacement, or
reciprocating pumps. Leaks from pumps typically occur at the
seal.
[0010] Sampling connections are utilized to obtain samples from
within a process. Leaks from sampling connections usually occur at
the outlet of the sampling valve when the sampling line is purged
to obtain the sample.
[0011] Compressors are designed to increase the pressure of a fluid
and provide motive force. They can have rotary or reciprocating
designs. Leaks from compressors most often occur from the
seals.
[0012] Pressure-relief devices are safety devices designed to
protect equipment from exceeding the maximum allowable working
pressure. Pressure relief valves and rupture disks are examples of
pressure relief devices. Leaks from pressure relief valves can
occur if the valve is not sealed properly, operating too close to
the set point, or if the seal is worn or damaged. Leaks from
rupture disks can occur around the disk gasket if not properly
installed.
[0013] Open-ended lines are pipes or hoses open to the atmosphere
or surrounding environment. Leaks from open-ended lines occur at
the point of the line open to the atmosphere and are usually
controlled by using caps, plugs, and flanges. Leaks can also be
caused by the incorrect implementation of the block and bleed
procedure.
[0014] In a typical facility, most of the emissions are from valves
and pumps because of moving parts inside. The major cause of
emissions is seal or gasket failure due to normal wear or improper
maintenance.
[0015] Facilities can control emissions from equipment leaks by
implementing a leak detection and repair ("LDAR") program. LDAR is
a work practice designed to identify leaking equipment so that
emissions can be reduced through repairs. A component that is
subject to LDAR requirements must be monitored at specified,
regular intervals to determine whether it is leaking. Any leaking
component must then be repaired or replaced within a specified
period of time.
[0016] Alternatively, or in conjunction with a LDAR program,
facilities can control emission from equipment leaks by
modifying/replacing leading equipment with "leakless" or "seal
less" components. Leakless and seal less components can be
effective at minimizing or eliminating leaks, but their use may be
limited by materials of construction considerations and process
operating conditions. Installing leakless and seal less components
can also be expensive and time-consuming, possibly even requiring a
shut-down of all or a part of a facility.
[0017] LDAR programs are required by many federal, state and local
requirements/standards/regulations ("Regulations"). Most these
Regulations require the implementation of a formal LDAR program
using EPA Reference Method 21 (40 CFR Part 60, Appendix A) ("Method
21"). Facilities must also ensure that they are complying with the
proper equipment leak Regulations if multiple Regulations apply.
Emissions reductions from implementing a WAR program potentially
reduce product losses, increase safety for workers and operators,
decrease exposure of the surrounding community, reduce emissions
fees, and help facilities avoid enforcement actions.
[0018] While the requirements among the Regulations vary, all LDAR
programs consist of five basic elements, namely: (1) identifying
components; (2) leak definition; (3) monitoring components; (4)
repairing components; and (5) recordkeeping.
[0019] Identifying components generally includes the following
requirements: (a) assigning a unique identification (ID) number to
each regulated component; (b) recording each regulated component
and its unique ID number in a log; (c) physically locating each
regulated component in the facility, verifying its location on the
piping and instrumentation diagrams or process flow diagrams, and
updating the log if necessary (some states require a physical tag
on each component subject to the LDAR requirements); (d)
identifying each regulated component on a site plot plan or on a
continuously updated equipment log; and (e) promptly noting in the
equipment log when new and replacement pieces of equipment are
added and equipment is taken out of service.
[0020] As for leak definition, Method 21 requires VOC emissions
from regulated components to be measured in parts per million
("ppm"). A leak is detected whenever the measured concentration
exceeds the threshold standard (i.e., leak definition) for the
applicable regulation. Leak definitions vary by regulation,
component type, service (e.g., light liquid, heavy liquid,
gas/vapor), and monitoring interval. Some regulations New Source
Performance Standards ("NSPS")) have a leak definition of 10,000
ppm, while other regulations (e.g., National Emission Standards for
Hazardous Air Pollutants ("NESHAP")) use a 500 ppm or 1,000 ppm
leak definition. Many equipment leak regulations also define a leak
based on visual inspections and observations (such as fluids
dripping, spraying, misting, or clouding from or around
components), sound (such as hissing), and smell.
[0021] In connection with monitoring components, for many
Regulations with leak detection provisions, the primary method for
monitoring to detect leaking components is Method 21. Method 21 is
a procedure used to detect VOC leaks from process equipment using a
portable detecting instrument. Monitoring intervals vary according
to the applicable regulation, but are typically weekly, monthly,
quarterly, and yearly. The monitoring interval generally depends on
the component type and periodic leak rate for the component type.
In general, Method 21 requires three steps: (1) evaluating
instrument performance; (2) calibrating instrument; and (3)
monitoring individual components.
[0022] Evaluating instrument performance includes: (a) for each VOC
measured, the response factor should be <10 unless specified in
the applicable regulation. Response factor is the ratio of the
known concentration of a VOC compound to the observed meter reading
when measured using an instrument calibrated with the reference
compound specified in the applicable regulation; (b) the
calibration precision should be <10 percent of the calibration
gas value. Calibration precision is the degree of agreement between
measurements of the same known value, expressed as the relative
percentage of the average difference between the meter readings and
the known concentration to the known concentration; and (c) the
response time should be .ltoreq.30 seconds. Response time is the
time interval from a step change in VOC concentration at the input
of the sampling system to the time at which 90% of the
corresponding final value is reached as displayed on the instrument
readout meter.
[0023] Calibrating instrument includes performing the following
before each monitoring episode: (a) letting the instrument warm up;
(b) introducing the calibration gas into the instrument probe; and
(c) adjusting the instrument meter readout to match the calibration
gas concentration value.
[0024] Monitoring individual components includes: (a) placing the
probe at the surface of the component interface where leakage could
occur; (b) moving the probe along the interface periphery while
observing the instrument readout; (c) locating the maximum reading
by moving the probe around the interface; (d) keeping the probe at
the location of the maximum reading for two times the response
factor; and (e) if the concentration reading on the instrument
readout is above the applicable leak definition, then the component
is leaking and must be repaired.
[0025] Repairing components generally includes the following
requirements: (a) repairing leaking components as soon as
practicable, but not later than a specified number of calendar days
after the leak is detected; (b) if the repair of any component is
technically infeasible without a process unit shutdown, the
component may be placed on the Delay of Repair list, the ID number
is recorded, and an explanation of why the component cannot be
repaired immediately is provided. An estimated date for repairing
the component must be included in the facility records; and (c) the
component is considered to be repaired only after it has been
monitored and shown not to be leaking above the applicable leak
definition.
[0026] Recordkeeping, for each regulated process, includes: (a)
maintaining a list of all ID numbers for all equipment subject to
an equipment leak regulation; (b) for valves designated as "unsafe
to monitor," maintaining a list of ID numbers and an
explanation/review of conditions for the designation; (c)
maintaining detailed schematics, equipment design specifications
(including dates and descriptions of any changes), and piping and
instrumentation diagrams; and (d) maintaining the results of
performance testing and leak detection monitoring, including leak
monitoring results per the leak frequency, monitoring leakless
equipment, and non-periodic event monitoring.
[0027] Recordkeeping, for leaking equipment, includes: (a)
attaching ID tags to the equipment; (b) maintaining records of the
equipment ID number, the instrument and operator ID numbers, and
the date the leak was detected; (c) maintaining a list of the dates
of each repair attempt and an explanation of the attempted repair
method; (d) noting the dates of successful repairs; and (e)
including the results of monitoring tests to determine if the
repair was successful.
[0028] Attempts have been made to make improvements in LDAR
programs. One specific area of desired improvement is in connection
with the monitoring of individual components. A single process
plant can have hundreds of thousands of components, each of which
must be monitored for leakage. While the manual use of a probe is
an effective way of monitoring the components for leaks, the manual
use has several disadvantages associated with it. More
specifically, the manual use of a probe is typically performed by a
large pool of skilled labor and/or engineers and, thus, tends to
have high associated costs to execute, especially as the manual use
of a probe to monitor hundreds of thousands of components can be
rather time consuming.
[0029] In an effort to promote efficiency and reduce costs, gas
cameras based on infrared absorption have been developed to quickly
scan components. Examples are FLIR model GF300 & 320, and Opgal
model EyeCGas. These infrared cameras are fast in identifying
locations of large leaks, but they do not provide quantitative
results and they do not offer the same level of sensitivity as
conventional Method 21 instruments. Therefore, the EPA approved the
use of gas imaging devices as an alternative work practice (AWP)
but still requires refineries to perform inspections using a
"sniffer" type instrument.
[0030] Some refineries and chemical plants may have fixed gas
detection systems to monitor certain areas. These systems, however,
suffer from outdoor environmental conditions, such as wind, rain,
and temperature variations. For example, the effect of wind at a
leaking valve is illustrated in FIG. 1. FIG. 1 was generated using
ANSYS finite element analysis (FEA) simulations. Depending on the
position of the sensor on the valve with respect to the point where
the leak is occurring, the sensor's reading may vary from hundreds
of parts per million (ppm) down to a few parts per billion (ppb)
levels. In order to detect and quantify the leak, the sensor must
be placed exactly at the leak location, but the odds of this
occurring are not likely and, furthermore, those odds are not odds
that are acceptable to the process plants and/or the EPA. Since the
negatives associated with using sensors have not been overcome, the
tried-and-true method of manual monitoring with an expensive
handheld device to reliably locate and quantify the leak continue
to be used.
[0031] As a result of the foregoing, certain individuals would
appreciate further improvements in LDAR programs, including the use
of leak detection sensors and assemblies, and systems utilizing
same.
SUMMARY
[0032] In an embodiment, the present disclosure provides a leak
sensor assembly which is configured to detect the leakage of gas
from a component of a piping system. The leak sensor assembly
includes a housing and at least one sensor. The housing is
configured to be positioned proximate to the component and forms a
pocket which allows gas leaked from the component to concentrate
within the pocket in a generally uniform dispersion. The at least
one sensor is configured to detect the presence and concentration
of gas within the pocket of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The present disclosure is illustrated by way of example and
not limited in the accompanying figures in which like reference
numerals indicate similar elements and in which:
[0034] FIG. 1 illustrates the effect of wind on a leak at a point
on a valve using ANSYS finite element analysis (FEA)
simulations;
[0035] FIG. 2A is a perspective view of a first part of a prior art
piping system;
[0036] FIG. 2B is a perspective view of a body of the first part of
the prior art piping system;
[0037] FIG. 3A is a perspective view of a second part of a prior
art piping system;
[0038] FIG. 3B is a perspective view of a connector of the second
part of the prior art piping system;
[0039] FIG. 4 is a perspective view of a third part of a prior art
piping system;
[0040] FIG. 5 is a block diagram showing a sensor of the leak
sensor assembly in communication with a control unit;
[0041] FIG. 6 is a block diagram showing a sensor of the leak
sensor assembly as part of a sensor network;
[0042] FIG. 7 is a perspective view of a first embodiment of a leak
sensor assembly attached to the piping system;
[0043] FIGS. 8 and 9 are perspective views of a housing of the leak
sensor assembly of FIG. 7;
[0044] FIG. 10 is a cross-sectional view of the leak sensor
assembly of FIG. 7 attached to the piping system;
[0045] FIGS. 11 and 12 are perspective views of a second embodiment
of a leak sensor assembly attached to the piping system;
[0046] FIG. 13 is a plan view of the leak sensor assembly of FIGS.
11 and 12;
[0047] FIG. 14 is an exploded perspective view of a housing of the
leak sensor assembly of FIGS. 11 and 12;
[0048] FIG. 15 is a perspective view of a half of the housing of
FIG. 14;
[0049] FIG. 16 is a side elevation view of the leak sensor assembly
of FIGS. 11 and 12 attached to the piping system and with a half of
the housing removed;
[0050] FIG. 17 is a perspective view of a third embodiment of a
leak sensor assembly attached to the piping system;
[0051] FIGS. 18 and 19 are perspective views of a housing of the
leak sensor assembly of FIG. 17;
[0052] FIG. 20 is a perspective view of the housing of FIGS. 18 and
19 showing the housing in two halves, but joined together along a
line;
[0053] FIG. 21 is a perspective view of the housing of FIGS. 18 and
19 showing the housing in two separate halves;
[0054] FIG. 22 is a perspective view of a fourth embodiment of a
leak sensor assembly attached to the piping system;
[0055] FIG. 23 is cross-sectional view of a modified leak sensor
assembly of FIG. 22 attached to the piping system;
[0056] FIG. 24 is a perspective view showing a filler within the
housing of FIGS. 8 and 9;
[0057] FIGS. 25-28 are perspective views of the leak sensor
assemblies showing a drain opening;
[0058] FIG. 29 is a perspective view showing the housing of FIGS.
18-21 with a collar assembly exploded therefrom which is used to
releasably attach the sensor to the housing;
[0059] FIG. 30 is a perspective view showing the housing of FIGS.
18-21 with the collar assembly of FIG. 29 partially attached
thereto;
[0060] FIGS. 31 and 32 are perspective views showing the housing of
FIGS. 18-21 with the collar assembly attached thereto and showing
the sensor;
[0061] FIG. 33 is a perspective view of a collar of the collar
assembly of FIG. 29;
[0062] FIG. 34 is a perspective view of a fifth embodiment of a
leak sensor assembly attached to the piping system;
[0063] FIG. 35 is a cross-sectional view of a housing of the leak
sensor assembly shown in FIG. 34;
[0064] FIG. 36 is a perspective view of the housing of the leak
sensor assembly shown in FIG. 34;
[0065] FIG. 37 is an end view of a housing of the leak sensor
assembly shown in FIG. 34;
[0066] FIG. 38 is an end view of a housing of the leak sensor
assembly shown in FIG. 34 with the sensor partially engaged;
[0067] FIG. 39 is a perspective view of a modified fifth embodiment
of a leak sensor assembly attached to the piping system;
[0068] FIG. 40 is an exploded perspective view of the modified leak
sensor assembly of FIG. 38;
[0069] FIG. 41 is a partial cross-sectional view of a sixth
embodiment of a leak sensor assembly; and
[0070] FIG. 42 is a perspective view of a seventh embodiment of a
leak sensor assembly.
DETAILED DESCRIPTION
[0071] While the disclosure may be susceptible to embodiment in
different forms, there is shown in the drawings, and herein will be
described in detail, specific embodiments with the understanding
that the present disclosure is to be considered an exemplification
of the principles of the disclosure, and is not intended to limit
the disclosure to that as illustrated and described herein.
Therefore, unless otherwise noted, features disclosed herein may be
combined together to form additional combinations that were not
otherwise shown for purposes of brevity. It will be further
appreciated that in some embodiments, one or more elements
illustrated by way of example in a drawing(s) may be eliminated
and/or substituted with alternative elements within the scope of
the disclosure.
[0072] The present disclosure provides embodiments of a leak sensor
assembly 100, 200, 300, 400, 500, 600, 700 which can be used to
detect leaks occurring at various components of a piping system
that are typically found in a process plant, such as valves 20 and
connectors 22, 22' connected to pipes 28, 30, 50. Within a process
plant, one or more elaborate piping systems are provided for
delivering and managing the flow of liquid and gas materials. These
piping systems include a plurality of valves 20 which are
configured to control the flow of the material through the pipes
28, 30 of the piping systems, and connectors 22, 22' which are
configured to direct the flow of the material through the pipes 28,
30/pipes 28, 30, 50 within the piping systems. Each valve 20 can be
an on/off valve (which either allows for the flow of material past
the valve 20 or prevents the flow of material past the valve 20)
and/or can be a throttling valve (which controls the flow rate of
the material past the valve 20). The valve 20 can be any known type
of valve, such as a gate valve or a globe valve.
[0073] FIGS. 2A and 2B illustrate a first portion 26a of the piping
system. The first portion 26a includes a first pipe 28, a second
pipe 30, and the valve 20. The valve 20 includes a generally hollow
body 32 having first, second and third openings 34, 36, 38 at first
and second ends 40, 42 along the length of the valve 20 between the
first and second ends 40, 42. The first pipe 28 extends into the
first opening 34 and is secured to the first end 40 of the body 32
in a known manner, for example by threading, and the second pipe 30
extends into the second opening 36 and is secured to the second end
42 of the body 32 in a known manner, for example by threading.
Thus, a desired material, whether it be a fluid, gas, or slurry,
can flow into the body 32 of the valve 20 from the first pipe 28,
and thereafter can flow out of the body 32 of the valve 2.0 and
into the second pipe 30 for further delivery downstream in the
piping system. The valve 20 further includes a bonnet 44 which is
configured to close off the opening 38 of the valve 20. The bonnet
44 may be screwed into the body 32 so as to enable any sort of
maintenance or repair work to be done without having to remove the
entire valve 20 from the piping system. The bonnet 44 further
houses other internal parts of the valve 20 to allow for its
desired operation. The valve 20 further includes a stem 46 and a
handwheel 48. The stem 46 extends downwardly from the handwheel 48
and at least a portion of the stem 46 is housed by the bonnet 44.
The handwheel 48 is generally circular in configuration and is used
to control the stem 46 which, in turn, controls/prevents/allows the
flow of material through the body 32 of the valve 20. Typically,
the handwheel 48 is turned clockwise to "close" the valve 20 and
counter-clockwise to "open" the valve 20. Thus, a desired material,
whether it be a fluid, gas, or slurry, can flow into the body 32 of
the valve 20 from the first pipe 28, and thereafter can flow out of
the body 32 of the valve 20 and into the second pipe 30 for further
delivery downstream in the piping system. The connection between
the bonnet 44 and the body 32, and the connection between the
bonnet 44 and the stem 46, are understood to be the two most likely
places where leaks on the valve 20 will occur. Leaks may also occur
between the pipes 28, 30 and the body 32. While the pipes 28, 30
are shown being aligned in FIG. 2A, it is to be understood that the
pipes 28, 30 may be an angle relative to each other.
[0074] FIGS. 3A and 3B illustrate a second portion 26b of the
piping system. The second portion 26b includes a first pipe 28, a
second pipe 30, a third pipe 50 and the connector 22. The connector
22 includes a generally hollow body 52 which has openings 54, 56,
58 at its first and second ends 60, 62 along the length of the
connector 22 between the first and second ends 60, 62. The first
pipe 28 extends into the first opening 54 and is secured to the
first end 60 of the body 52 in a known manner, for example by
threading; the second pipe 30 extends into the second opening 56
and is secured to the second end 62 of the body 52 in a known
manner, for example by threading; and the third pipe 50 extends
into the third opening 58 and is secured to the body 52 in a known
manner, for example by threading. While the pipes 28, 30 are shown
being aligned in FIG. 3A, it is to be understood that the pipes 28,
30 may be an angle relative to each other. While pipe 50 is shown
as being perpendicular to the pipes 28, 30 in FIG. 3A, the pipe 50
may be at other angles relative to the pipes 28, 30. Thus, a
desired material, whether it be a fluid, gas, or slurry, can flow
into the body 52 of the connector 22 from the first pipe 28, and
thereafter can flow out of the body 52 of the connector 22 and into
the second or third pipes 30, 50 for further delivery downstream in
the piping system. The connection between the pipes 28, 30, 50 and
the body 52 of the connector 22 provide possible leak paths.
[0075] FIG. 4 illustrates a third portion 26c of the piping system.
The third portion 26c includes a first pipe 28, a second pipe 30
and the connector 22'. The connector 22' is identically formed to
the connector 22, except that the third opening 58 of the connector
22 is eliminated in connector 22'. Therefore, identical components
of the connector 22' are labeled with the same reference numerals
as for the connector 22, but with a prime after the reference
numeral. Thus, a desired material, whether it be a fluid, gas, or
slurry, can flow into the body 52' of the connector 22' from the
first pipe 28, and thereafter can flow out of the body 52' of the
connector 22' and into the second pipe 30 for further delivery
downstream in the piping system. The connection between the pipes
28, 30 and the body 52' of the connector 22' provide possible leak
paths.
[0076] While FIGS. 3A-4 show connectors 22, 22' which are
configured to connect two and three pipes together, a connector
(not shown) could be provided to connect four pipes together as is
known in the art.
[0077] While the portions 26a, 26b, 26c are shown in a particular
orientation in FIGS. 1-4, this does not denote a required
orientation in use. That is, pipes 28, 30, 50 and valve stem 46 can
be at any angle relative to the ground. For example, it appears
that the handwheel 48 or the third pipe 50 is vertical in some of
the figures; this does not denote a required orientation.
[0078] FIGS. 7-10 illustrate a first embodiment of the leak sensor
assembly 100. FIGS. 11-16 disclose a second embodiment of the leak
sensor assembly 200. FIGS. 17-21 illustrate a third embodiment of
the leak sensor assembly 300. FIG. 22 illustrates a fourth
embodiment of the leak sensor assembly 400. FIG. 23 illustrates a
modification to the fourth embodiment of the leak sensor assembly
400. FIGS. 34-40 illustrate a fifth embodiment of the leak sensor
assembly 500. FIG. 41 illustrates a sixth embodiment of the leak
sensor assembly 600. FIG. 42 illustrates a seventh embodiment of
the leak sensor assembly 700.
[0079] Each embodiment of the leak sensor assembly 100, 200, 300,
400, 500, 600, 700 includes a sensor 64 and a housing 102, 202,
302, 402, 502, 702 configured to position the sensor 64 in close
proximity to one of the portions 26a, 26b, 26c of the piping
system. The housing 102, 202, 302, 402, 502, 702 forms a pocket
104, 204, 304, 404, 504 into which VOCs accumulate so that the
sensor 64 can detect the presence and concentration level of the
VOCs.
[0080] The sensor 64 can be any type of appropriate sensor which is
configured to detect volatile organic compounds VOCs, such as
infrared, catalytic oxidation, electrochemical, a colorimetric
sensor, metal oxide semiconductor (MOS), photoionization detector
(PID), a surface acoustic wave sensor, and other chemiresistive
sensors. Photoionization detectors, for example, are capable of
detecting many VOCs down to sub-ppm level. Electrochemical sensors
offer ppm resolution to certain types of VOCs. Infrared sensors are
very stable and are particularly suitable for long term, unattended
operation. They can detect most VOCs due to characteristic infrared
absorption of the hydrocarbon compounds. The sensor 64 could be
wired/wirelessly connected to a control unit 68, see FIG. 5, in
order to provide information regarding the readings of the sensor
64. The sensor 64 could also be a part of an overall sensor network
70, see FIG. 6, applied across the entire piping system or process
plant.
[0081] Attention is directed to FIGS. 7-10 and the first embodiment
of the leak sensor assembly 100 of the present disclosure. While
this embodiment is shown with the first portion 26a of the piping
system shown in FIGS. 2A and 2B, this first embodiment can be used
with the second or third portions 26b, 26c of the piping system
shown in FIGS. 3A, 3B and 4.
[0082] The housing 102 is formed from a wall 106 having first and
second ends 108, 110, and an inner wall surface 112 and an outer
wall surface 114 extending between the ends 108, 110. A first
opening 116 is provided through the first end 108 of the wall 106
and a second opening 118 is provided through the second end 110 of
the wall 106. The wall 106 defines the pocket 104 therein into
which VOCs accumulate when the housing 102 is attached to the
piping system as described herein. A sensor opening 126 is provided
through the wall 106, and extends from an inner wall surface to the
outer wall surface of the wall 106 and is in fluid communication
with the pocket 104. The sensor 64 is positioned and held in place
within the sensor opening 126 of the housing 102 such that the
sensor 64 is configured to detect VOCs within the pocket 104.
[0083] In an embodiment, the wall 106 is formed of a rigid and/or
semi-rigid material, such as metal, ceramic, thermoplastic
(acrylonitrile butadiene styrene (ABS), Noryl, polyethylene,
polypropylene, polyvinyl chloride (PVC), polycarbonate, etc.), and
particularly high temperature plastics such as liquid crystal
polymer (LCP), syndiotactic polystyrene (SPS), polyvinylidene
fluoride (PVDF), nylon, and durable high-performance
polyimide-based plastics, such as those sold under the registered
trademark VESPEL. The material of the wall 106 is also preferably
water-proof, weather-proof (e.g., resistant to the formation of
cracks, deformation, etc. upon prolonged exposure to the elements),
and chemically resistant to organic compounds. The material of the
housing 102 can further desirably withstand a wide temperature
range, for example, -40.degree. Celsius to 200.degree. Celsius. The
housing 102 may be formed of one consistent material or may be
formed of layers of materials. The layers of materials may be
different.
[0084] In an embodiment, the inner wall surface 112 is circular in
cross-section, yet conical in configuration from the first opening
116 to the second opening 118. In an embodiment, the outer wall
surface 114 matches the configuration of the inner wall surface
112, but the outer wall surface 114 can have any desired
configuration, regardless of whether it matches the configuration
of the inner wall surface 112.
[0085] In an embodiment as illustrated in FIGS. 8 and 9, the
housing 102 is formed of two halves 120, 122 which are joined
together by suitable securing means 124. In an embodiment, each
half 120, 122 is shaped as generally a half of a frusto-conical
shape such that when the two halves 120, 122 are mated, a
frusto-conical shape is formed. The two halves 120, 122 could be
hinged/flexible such that the two halves 120, 122 are joined or
integrally formed at line 125 which extends from opening 116 to
opening 118, but the two halves 120, 122 are separated along the
remainder of the intersection between the two halves 120, 122; such
the two halves 120, 122 can open and close similar to a clam shell
along line 125, and such that when closed the two halves 120, 122
are further joined together by the securing means 124. That is, the
housing 102 is formed of a single part which can be opened or
closed. The two halves 120, 122 can be completely separate from
each other and joined together by the securing means 124. The two
halves 120, 122 can be secured to one another using any suitable
securing means 124, including, but not limited to, fasteners,
latches (as shown), tape, hook-and-loop fasteners (such as those
sold under the registered trademark VELCRO), magnets, snaps,
buttons, etc. The suitable securing means 124 are also preferably
ones that allow for the housing 102 to be removed and reinstalled
as desired. In other words, the housing 102 is preferably reusable.
In an embodiment, the sensor opening 126 is provided through the
wall 106 and extends from the inner wall surface 112 to the outer
wall surface 114 and is in fluid communication with the pocket 104.
The sensor opening 126 is separated from the first and second
openings 116, 118. The sensor opening 126 may be provided at a
midpoint of the wall 106 between the first and second openings 116,
118. The sensor opening 126 is sized and positioned based on the
sensor 64 to be used and the desired location of the sensor 64. The
sensor 64 is configured to be positioned and held in place within
the sensor opening 126 of the housing 102 such that the sensor 64
is configured to detect VOCs within the pocket 104.
[0086] As shown in FIG. 7, the leak sensor assembly 100 is attached
to the first portion 26a of the piping system. The housing 102 is
configured to be generally positioned such that a portion of the
valve 20 seats within the pocket 104. In an embodiment, the stern
46 seats within the first opening 116 and the bonnet 44 and at
least a portion of the body 32 seats within the second opening 118
such that the stern 46, the connection between the stem 46 and the
bonnet 44, the bonnet 44, and the connection between the bonnet 44
and the body 32 are generally enclosed by the housing 102. The
first opening 116 may be sized to fit loosely around the stem 46 or
in close proximity to the stem 46; the second opening 118 may be
sized to fit loosely around the body 32 or in close proximity to
the body 32.
[0087] When the housing 102 is attached to the second portion 26b
of the piping system, the housing 102 is configured to be generally
positioned such that a portion of one of the pipes 28, 30, 50 and a
portion of the connector 22 seats within the pocket 104. In an
embodiment, the pipe 28, 30 or 50 seats within the first opening
116 and the body 52 of the connector 22 seats within the second
opening 118 such that the connection between the pipe 28, 30 or 50
and the body 52 are generally enclosed by the housing 102. The
first opening 116 may be sized to fit loosely around the pipe 28,
30 or 50 or in close proximity to the pipe 28, 30 or 50; the second
opening 118 may be sized to fit loosely around the body or in close
proximity to the body 52.
[0088] When the housing 102 is attached to the third portion 26c of
the piping system, the housing 102 is configured to be generally
positioned such that the connector 22' seats within the pocket 104.
In an embodiment, the first pipe 28 seats within the first opening
116 and the connector 22' seats within the pocket 104, and the
second pipe 30 seats within the second opening 118 such that the
connections between the connector 22' and the pipes 28, 30 are
generally enclosed by the housing 102. The first opening 116 may be
sized to fit loosely around the first pipe 28 or in close proximity
to the first pipe 28; the second opening 118 may be sized to fit
loosely around the second pipe 30 or in close proximity to the
second pipe 30. In an embodiment, the first pipe 28 seats within
the first opening 116 and the connector 22' seats within the pocket
104, and the body 52' of the connector 22' seats within the second
opening 118 such that the connections between the connector 22' and
the pipe 28 are generally enclosed by the housing 102. The first
opening 116 may be sized to fit loosely around the first pipe 28 or
in close proximity to the first pipe 28; the second opening 118 may
be sized to fit loosely around the body 52' of the connector 22' or
in close proximity to the body 52' of the connector 22'.
[0089] The frusto-conical/conical shape of some embodiments of the
inner wall 114 aids in limiting moisture accumulation in the pocket
104 as the moisture runs off. Of course, it is to be understood
that while the inner wall 114 is identified as being
frusto-conical/conical in shape, the inner wall 114 could take on
any other desired shape, or any other shape that is dictated by the
configuration of the valve 20 so as to maintain the desired volume
of the pocket 104.
[0090] Attention is directed to FIGS. 11-16 and a second embodiment
of the leak sensor assembly 200 of the present disclosure. While
this embodiment is shown with the second portion 26b of the piping
system shown in FIGS. 3A and 3B, this second embodiment can be used
with the first or third portions 26a, 26c of the piping system
shown in FIGS. 2A, 2B and 4.
[0091] The housing 202 is formed from a wall 206 having first,
second, third and fourth spaced apart openings 240, 242, 244, 246
provided therethrough. In an embodiment, adjacent openings 240,
242, 244, 246 are 90 degrees apart from each other. The wall 206
defines the pocket 204 therein into which VOCs accumulate when the
housing 202 is attached to the piping system as described herein. A
sensor opening 226 is provided through the wall 206, and extends
from an inner wall surface to the outer wall surface of the wall
206 and is in fluid communication with the pocket 204. The sensor
64 is positioned and held in place within the sensor opening 226 of
the housing 202 such that the sensor 64 is configured to detect
VOCs within the pocket 204.
[0092] In an embodiment, the wall 206 is formed of a rigid and/or
semi-rigid material, such as metal, ceramic, thermoplastic
(acrylonitrile butadiene styrene (ABS), Noryl, polyethylene,
polypropylene, polyvinyl chloride (PVC), polycarbonate, etc.), and
particularly high temperature plastics such as liquid crystal
polymer (LCP), syndiotactic polystyrene (SPS), polyvinylidene
fluoride (PVDF), nylon, and durable high-performance
polyimide-based plastics, such as those sold under the registered
trademark VESPEL. The material of the wall 206 is also preferably
water-proof, weather-proof (e.g., resistant to the formation of
cracks, deformation, etc. upon prolonged exposure to the elements),
and chemically resistant to organic compounds. The material of the
housing 202 can further desirably withstand a wide temperature
range, for example, -40.degree. Celsius to 200.degree. Celsius. The
wall may be formed of one consistent material or may be formed of
layers of materials. The layers of materials may be different.
[0093] In an embodiment, the housing 202 is formed of two halves
220, 22.2 which are joined together by suitable securing means 224.
The two halves 220, 222 could be hinged/flexible such that the two
halves 220, 222 are joined or integrally formed at line 225 which
extends from opening 240 to opening 242, for example, but the two
halves 220, 222 are separated along the remainder of the
intersection between the two halves 220, 222; such the two halves
220, 222 can open and close similar to a clam shell along line 225,
and such that when closed the two halves 220, 222 are further
joined together by the securing means 224. That is, the housing 202
is formed of a single part which can be opened or closed. In an
embodiment, when the line 225 is provided, the fourth opening is
eliminated. The two halves 220, 222 can be completely separate from
each other and joined together by the securing means 224. The two
halves 220, 222 can be secured to one another using any suitable
securing means 224, including, but not limited to, fasteners,
latches (as shown), tape, hook-and-loop fasteners (such as those
sold under the registered trademark VELCRO), magnets, snaps,
buttons, etc. The suitable securing means 224 are also preferably
ones that allow for the housing 202 to be removed and reinstalled
as desired. In other words, the housing 202 is preferably
reusable.
[0094] Each half 220, 222 includes a base wall 228 having a side
wall 230 extending outwardly therefrom such that a recess 232 is
formed within each half 220, 222. The base wall 228 has an outer
wall surface 228a, an inner wall surface 228c and an outer edge
228c. In an embodiment, the side wall 230 extends from the outer
edge 228c. The side wall 230 has an outer wall surface 230a, an
inner wall surface 230b, and an end surface 230c. The end surface
230c of the side wall 230 forms four half openings 234a, 234b,
234c, 234d which extend toward the base wall 228 and are sized to
approximate the shapes of the pipes 28, 30, 50 and/or the stem 46
(and/or the fourth pipe if provided). In an embodiment, the half
openings 234a, 234b, 234c, 234d are half circles. In an embodiment,
the first half 220 has an opening 236 into which a plug 238 is
seated. The opening 236 and plug 238 may be eliminated. In an
embodiment, each base wall 228 is square and each side wall 230 is
formed of four wall portions which are joined together at corners.
In an embodiment, each base wall 228 is circular and each side wall
230 is cylindrical. Other shapes for the walls 228, 230 may be
provided. The outer wall surfaces 228a, 230a may match the
configuration of the inner wall surfaces 228b, 230b, but the outer
wall surfaces 228a, 230a can have any desired configuration,
regardless of whether it matches the configuration of the inner
wall surfaces 228b, 230b.
[0095] The end surfaces 230c of the halves 220, 222 ate together.
The recesses 232 align with each other to form the pocket 204
within the housing 202. The half openings 234a, 234b, 234c, 234d
align with each other to form the first, second, third and fourth
openings 240, 242, 244, 246. In an embodiment, a compressible
gasket 247 is provided between the end surfaces 230c of the halves
220, 222. In an embodiment, the gasket 247 is formed of foam or
rubber.
[0096] In an embodiment, the sensor opening 226 is provided through
one of the walls of the second half 222. In an embodiment, the
sensor opening 226 is provided through the base wall 228 of the
second half 222 and extends from the outer wall surface 228a to the
inner wall surface 228b and is in fluid communication with the
pocket 204. The sensor opening 226 is separated from the openings
240, 242, 244, 246. The sensor opening 226 may be provided at the
center of the base wall 228. The sensor opening 226 is sized and
positioned based on the sensor 64 to be used and the desired
location of the sensor 64. The sensor 64 is configured to be
positioned and held in place within the sensor opening 226 of the
housing 202 such that the sensor 64 is configured to detect VOCs
within the pocket 204.
[0097] As shown in FIGS. 11 and 12, the leak sensor assembly 200 is
attached to the second portion 26b of the piping system. The
housing 202 is configured to be generally positioned such that the
first pipe 28 seats in the first opening 240, the second pipe 30
seats in the second opening 242, and the third pipe 50 seats in the
third opening 244. As shown in FIGS. 11 and 12, the fourth opening
246 is not occupied by a pipe. As such, the connector 22 and an end
portion of each pipe 28, 30, 50 are within the pocket 204 and are
generally encapsulated/enclosed by the housing 202. The first
opening 240 may be sized to fit loosely around the first pipe 28 or
in close proximity to the first pipe 28; the second opening 242 may
be sized to fit loosely around the second pipe 30 or in close
proximity to the second pipe 30; the third opening 244 may be sized
to fit loosely around the third pipe 50 or in close proximity to
the third pipe 50. If a fourth pipe (not shown) was connected to
the connector 22, the fourth pipe would extend through the fourth
opening 246. If a fourth pipe is provided, the fourth opening 246
may be sized to fit loosely around this fourth pipe or in close
proximity to this fourth pipe. If a fourth pipe is not provided,
the fourth opening 246 may be closed with a plug 245. Compressible
gaskets 248, such as foam or rubber blocks, may be provided around
the pipes 28, 30, 50 (and the fourth pipe if provided).
[0098] When the housing 202 is attached to the first portion 26a of
the piping system, the housing 202 is configured to be generally
positioned such that the first pipe 28 seats in the first opening
240, the second pipe 30 seats in the second opening 242, and the
stem 46 seats within the third opening 244. As such, a portion of
the valve 20 and an end portion of each pipe 28, 30 are within the
pocket 204 and are generally encapsulated/enclosed by the housing
202. The first opening 240 may be sized to fit loosely around the
first pipe 28 or in close proximity to the first pipe 28; the
second opening 242 may be sized to fit loosely around the second
pipe 30 or in close proximity to the second pipe 30; and the third
opening 244 may be sized to fit loosely around the stem 46 or in
close proximity to the stem 46. If a fourth pipe (not shown) was
connected to the connector 22, the fourth pipe would extend through
the fourth opening 246. If a fourth pipe is provided, the fourth
opening 246 may be sized to fit loosely around this fourth pipe or
in close proximity to this fourth pipe. If a fourth pipe is not
provided, the fourth opening 246 may be closed with a plug 245.
Compressible gaskets 248, such as foam or rubber blocks, may be
provided around the pipes 28, 30, 50 (and the fourth pipe if
provided). Compressible gaskets 248, such as foam or rubber blocks,
may be provided around the pipes 28, 30 and the stem 46.
[0099] When the housing 202 is attached to the third portion 26c of
the piping system, the third and fourth openings 244, 246 are
eliminated or closed by suitable means, such as a plug. The housing
202 is configured to be generally positioned such that the first
pipe 28 seats in the first opening 240 and the second pipe 30 seats
in the second opening 242. As such, the connector 22' and an end
portion of each pipe 28, 30 are within the pocket 204 and are
generally encapsulated/enclosed by the housing 202. The first
opening 240 may be sized to fit loosely around the first pipe 28 or
in close proximity to the first pipe 28; the second opening 242 may
be sized to fit loosely around the second pipe 30 or in close
proximity to the second pipe 30. If a fourth pipe (not shown) was
connected to the connector 22, the fourth pipe would extend through
the fourth opening 246. If a fourth pipe is provided, the fourth
opening 246 may be sized to fit loosely around this fourth pipe or
in close proximity to this fourth pipe. If a fourth pipe is not
provided, the fourth opening 246 may be closed with a plug 245.
Compressible gaskets 248, such as foam or rubber blocks, may be
provided around the pipes 28, 30, 50 (and the fourth pipe if
provided). Compressible gaskets 248, such as foam or rubber blocks,
may be provided around the pipes 28, 30.
[0100] Attention is directed to FIGS. 17-21 and a third embodiment
of the leak sensor assembly 300 of the present disclosure. While
this embodiment is shown with the first portion 26a of the piping
system shown in FIGS. 2A and 2B, this third embodiment can be used
with the second or third portions 26b, 26c of the piping system
shown in FIGS. 3A, 3B and 4.
[0101] The housing 302 is formed from a wall 306 having an inner
wall surface and an outer wall surface, and first, second and third
spaced apart openings 340, 342, 344 provided therethrough. In an
embodiment, openings 340 and 344 are 90 degrees apart from each
other, openings 344 and 342 are 90 degrees apart from each other,
and openings 340 and 342 are aligned with each other. The wall 306
defines the pocket 304 therein into which VOCs accumulate when the
housing 302 is attached to the piping system as described herein. A
sensor opening 326 is provided through the wall 306, and extends
from an inner wall surface to the outer wall surface of the wall
306 and is in fluid communication with the pocket 304. The sensor
64 is positioned and held in place within the sensor opening 326 of
the housing 302 such that the sensor 64 is configured to detect
VOCs within the pocket 304.
[0102] The wall 306 is formed of flexible, breathable fabric, for
example, a fabric sold under the registered trademark TYVEK, a
non-woven fabric made of high density polyethylene fibers, or
fabrics sold under the registered trademarks TYPAR and CERTAWRAP,
which are fabrics made of spunbond polypropylene fibers, or fabrics
made of polyvinyl chloride (PVC) or polytetrafluoroethylene (PTFE),
such as a flexible fabric material sold under the registered
trademark TEFLON, or fabrics made of other fluorinated hydrocarbon
polymers. The material forming the wall 306 is preferably: (1)
microporous, such that it is gas permeable, but not liquid
permeable; (2) hydrophobic, such that it tends to repel water; (3)
water-proof; (4) weather-proof/weather-resistant (resistant to the
formation of cracks, deformation, etc. upon prolonged exposure to
the elements); (5) chemically stable, such that it is chemically
resistant to organic compounds; (6) anti-tear; and (7) able to
withstand a wide temperature range, for example, -40.degree.
Celsius to 200.degree. Celsius.
[0103] In an embodiment, the housing 302 is formed of two halves
320, 322 which are joined together by suitable securing means 324.
The two halves 320, 322 could be hinged/flexible such that the two
halves 320, 322 are joined or integrally formed at line 325 which
extends from opening 340 to opening 342, but the two halves 320,
322 are separated along the remainder of the intersection between
the two halves 320, 322; such the two halves 320, 322 can open and
dose similar to a clam shell along line 325, and such that when
closed the two halves 320, 322 are further joined together by the
securing means 324. That is, the housing 302 is formed of a single
part which can be opened or dosed. The two halves 320, 322 can be
completely separate from each other and joined together by the
securing means 324. The two halves 320, 322 can be secured to one
another using any suitable securing means 324, including, but not
limited to, fasteners, latches (as shown), tape, hook-and-loop
fasteners (such as those sold under the registered trademark
VELCRO), magnets, snaps, buttons, etc. The suitable securing means
324 are also preferably ones that allow for the housing 302 to be
removed and reinstalled as desired. In other words, the housing 302
is preferably reusable.
[0104] Each half 320, 322 includes a cup-shaped wall 328 forming a
recess 332 within each half 320, 322. The cup-shaped wall 328 has
an outer wall surface 328a, an inner wall surface 328b and an end
surface 328c. The cup-shaped wall 328 forms three half openings
334a, 334b, 334c which are sized to approximate the shapes of the
pipes 28, 30, 50 and/or the stem 46. In an embodiment, the half
openings 334a, 334b, 334c are half circles. The outer wall surfaces
328a may match the configuration of the inner wall surfaces 328b,
but the outer wall surfaces 328a can have any desired
configuration, regardless of whether it matches the configuration
of the inner wall surfaces 328b.
[0105] In an embodiment, the sensor opening 326 is provided through
the wall 328 of the second half 322 and extends from the outer wall
surface 328a to the inner wall surface 328b such that the sensor
opening 326 is in fluid communication with the pocket 304. The
sensor opening 326 is separated from the openings 340, 342, 344.
The sensor opening 326 may be provided at the center of the wall
328. The sensor opening 326 is sized and positioned based on the
sensor 64 to be used and the desired location of the sensor 64. The
sensor 64 is configured to be positioned and held in place within
the sensor opening 326 of the housing 302 such that the sensor 64
is configured to detect VOCs within the pocket 304.
[0106] The halves 320, 322 are wrapped around the piping system and
the end surfaces 328c of the halves 320, 322 mate together. The
halves 320, 322 are secured together by the securing means 324. The
recesses 332 align with each other to form the pocket 304 within
the housing 302. The half openings 334a, 334b, 334c align with each
other to form the first, second and third openings 340, 342, 344.
In an embodiment, a compressible gasket (not shown) provided
between the end surfaces 328c of the halves 320, 322. When the two
cup-shaped halves 320, 322 are mated, a generally ovoid shape is
formed for the pocket 304. Other shapes for the halves 320, 322 may
be provided.
[0107] As shown in FIG. 17, the leak sensor assembly 300 is
attached to the first portion 26a of the piping system shown in
FIGS. 2A and 2B. The housing 302 is configured to be generally
positioned such that the first pipe 28 seats in the first opening
340, the second pipe 30 seats in the second opening 342, and the
stem 46 seats in the third opening 344. As such, the valve 20 and
an end portion of each pipe 28, 30 are within the pocket 304 and
are generally enclosed by the housing 302. The first opening 340
may be sized to fit loosely around the first pipe 28 or in close
proximity to the first pipe 28; the second opening 342 may be sized
to fit loosely around the second pipe 30 or in close proximity to
the second pipe 30; the third opening 344 may be sized to fit
loosely around the stem 46 or in close proximity to the stem 46.
Compressible gaskets, such as foam or rubber blocks, may be
provided around the pipes 28, 30 and the stem 46.
[0108] When the housing 302 is attached to the second portion 26b
of the piping system, the housing 302 is configured to be generally
positioned such that the first pipe 28 seats in the first opening
340, the second pipe 30 seats in the second opening 342, and the
third pipe 50 seats within the third opening 344. As such, the
connector 2.2 and an end portion of each pipe 28, 30, 50 are within
the pocket 304 and are generally encapsulated/enclosed by the
housing 302. The first opening 340 may be sized to fit loosely
around the first pipe 28 or in close proximity to the first pipe
28; the second opening 342 may be sized to fit loosely around the
second pipe 30 or in close proximity to the second pipe 30; and the
third opening 344 may be sized to fit loosely around the third pipe
50 or in close proximity to the third pipe 50. Compressible gaskets
348, such as foam or rubber blocks, may be provided around the
pipes 28, 30, 50.
[0109] When the housing 302 is attached to the third portion 26c of
the piping system, the third and fourth openings 244, 246 are
eliminated or closed by suitable means, such as a plug. The housing
302 is configured to be generally positioned such that the first
pipe 28 seats in the first opening 340 and the second pipe 30 seats
in the second opening 342. As such, the connector 22' and an end
portion of each pipe 28, 30 are within the pocket 304 and are
generally encapsulated/enclosed by the housing 302. The first
opening 340 may be sized to fit loosely around the first pipe 28 or
in close proximity to the first pipe 28; the second opening 342 may
be sized to fit loosely around the second pipe 30 or in close
proximity to the second pipe 30. Compressible gaskets 348, such as
foam or rubber blocks, may be provided around the pipes 28, 30.
[0110] In an embodiment, the wall 306 of the housing 302 has a
fourth opening (not shown) provided therethrough to accommodate a
fourth pipe (not shown). If the fourth opening is provided and the
fourth pipe is not provided, the fourth opening may be closed with
a plug (not shown).
[0111] Attention is directed to FIG. 22 and a fourth embodiment of
the leak sensor assembly 400 of the present disclosure. While this
embodiment is shown with the first portion 26a of the piping system
shown in FIGS. 2A and 2B, this fourth embodiment can be used with
the second or third portions 26b, 26c of the piping system shown in
FIGS. 3A, 3B and 4.
[0112] The housing 402 is formed from a wall 406 having first and
second ends, and an inner wall surface 412 and an outer wall
surface 414 extending between the ends. A first opening 416 is
provided through the first end of the wall 406 and a second opening
418 is provided through the second end of the wall 406. The wall
406 defines the pocket 404 therein into which VOCs accumulate when
the housing 402 is attached to the piping system as described
herein. A sensor opening (not shown) is provided through the wall
406, and extends from an inner wall surface to the outer wall
surface of the wall 406 and is in fluid communication with the
pocket 404. The sensor 64 is positioned and held in place within
the sensor opening of the housing 402 such that the sensor 64 is
configured to detect VOCs within the pocket 404.
[0113] The wall 406 is formed of flexible, breathable fabric, for
example, a fabric sold under the registered trademark TYVEK, a
non-woven fabric made of high density polyethylene fibers, or
fabrics sold under the registered trademarks TYPAR and CERTAWRAP,
which are fabrics made of spunbond polypropylene fibers, or fabrics
made of polyvinyl chloride (PVC) or polytetrafluoroethylene (PUT),
such as a flexible fabric material sold under the registered
trademark TEFLON, or fabrics made of other fluorinated hydrocarbon
polymers. The material forming the wall 406 is preferably: (1)
microporous, such that it is gas permeable, but not liquid
permeable; (2) hydrophobic, such that it tends to repel water; (3)
water-proof; (4) weather-proof/weather-resistant (resistant to the
formation of cracks, deformation, etc. upon prolonged exposure to
the elements); (5) chemically stable, such that it is chemically
resistant to organic compounds; (6) anti-tear; and (7) able to
withstand a wide temperature range, for example, -40.degree.
Celsius to 200.degree. Celsius.
[0114] In an embodiment, the inner wall surface 412 is circular in
cross-section, yet conical in configuration from the first opening
416 to the second opening 418. In an embodiment, the outer wall
surface 414 matches the configuration of the inner wall surface
412, but the outer wall surface 414 can have any desired
configuration, regardless of whether it matches the configuration
of the inner wall surface 412.
[0115] In an embodiment, the housing 402 is formed of two halves
(not shown) which are joined together by suitable securing means
(not shown). The two halves could be hinged/flexible such that the
two halves are joined or integrally formed at line (not shown)
which extends from opening 416 to opening 418, but the two halves
are separated along the remainder of the intersection between the
two halves; such the two halves can open and close similar to a
clam shell along line, and such that when closed the two halves are
further joined together by the securing means. That is, the housing
402 is formed of a single part which can be opened or closed. The
two halves can be completely separate from each other and joined
together by the securing means. The two halves can be secured to
one another using any suitable securing means, including, but not
limited to, fasteners, latches (as shown), tape, hook-and-loop
fasteners (such as those sold under the registered trademark
VELCRO), magnets, snaps, buttons, etc. The suitable securing means
are also preferably ones that allow for the housing 402 to be
removed and reinstalled as desired. In other words, the housing 402
is preferably reusable. In an embodiment, the sensor opening is
provided through the wall 406 and extends from the inner wall
surface 412 to the outer wall surface 414 and is in fluid
communication with the pocket 404. The sensor opening is separated
from the first and second openings 416, 418. The sensor opening may
be provided at a midpoint of the wall 406 between the first and
second openings 416, 418. The sensor opening is sized and
positioned based on the sensor 64 to be used and the desired
location of the sensor 64. The sensor 64 is configured to be
positioned and held in place within the sensor opening of the
housing 402 such that the sensor 64 is configured to detect VOCs
within the pocket 404.
[0116] As shown in FIG. 22, the leak sensor assembly 400 is
attached to the first portion 26a of the piping system. The housing
402 is configured to be generally positioned such that a portion of
the valve 20 seats within the pocket 404. In an embodiment, the
stem 46 seats within the first opening 416 and the bonnet 44 and at
least a portion of the body 32 seats within the second opening 418
such that the stem 46, the connection between the stem 46 and the
bonnet 44, the bonnet 44, and the connection between the bonnet 44
and the body 32 are generally enclosed by the housing 402. The
first opening 416 may be sized to fit loosely around the stem 46 or
in close proximity to the stern 46; the second opening 418 may be
sized to fit loosely around the body 32 or in close proximity to
the body 32.
[0117] When the housing 402 is attached to the second portion 26b
of the piping system, the housing 402 is configured to be generally
positioned such that a portion of one of the pipes 28, 30, 50 and a
portion of the connector 2.2 seats within the pocket 404. In an
embodiment, the pipe 28, 30 or 50 seats within the first opening
416 and the body 52 of the connector 22 seats within the second
opening 418 such that the connection between the pipe 28, 30 or 50
and the body 52 are generally enclosed by the housing 402. The
first opening 416 may be sized to fit loosely around the pipe 28,
30 or 50 or in close proximity to the pipe 28, 30 or 50; the second
opening 418 may be sized to fit loosely around the body or in close
proximity to the body 52.
[0118] When the housing 402 is attached to the third portion 26c of
the piping system, the housing 402 is configured to be generally
positioned such that the connector 22' seats within the pocket 404.
In an embodiment, the first pipe 28 seats within the first opening
416 and the connector 22' seats within the pocket 404, and the
second pipe 30 seats within the second opening 418 such that the
connections between the connector 22' and the pipes 28, 30 are
generally enclosed by the housing 402. The first opening 416 may be
sized to fit loosely around the first pipe 28 or in close proximity
to the first pipe 28; the second opening 418 may be sized to fit
loosely around the second pipe 30 or in close proximity to the
second pipe 30. In an embodiment, the first pipe 28 seats within
the first opening 416 and the connector 22' seats within the pocket
404, and the body 52' of the connector 22' seats within the second
opening 418 such that the connections between the connector 22' and
the pipe 28 are generally enclosed by the housing 402. The first
opening 416 may be sized to fit loosely around the first pipe 28 or
in close proximity to the first pipe 28; the second opening 418 may
be sized to fit loosely around the body 52' of the connector 22' or
in close proximity to the body 52' of the connector 22'.
[0119] In an embodiment, the inner wall 414 of the housing 402 is
circular in cross-section, yet conical in configuration from the
first end of the housing 402 to a middle portion of the housing
402, and conical in configuration from the middle portion of the
housing 402 to the second end of the housing 402. A multi-conical
shape aids in limiting moisture accumulation in the pocket 404. Of
course, it is to be understood that while the inner wall 414 is
identified as being multi-conical in shape, the inner wall 414
could take on any other desired shape, or any other shape that is
dictated by the configuration of the component, e.g., the valve 20,
so as to maintain the desired volume of the pocket 404. For
example, in an embodiment, the inner wall 414 of the housing 402 is
spherical.
[0120] FIG. 23 shows that the housing 402 includes a framework 450
which is preferably rigid in configuration. The framework 450 may
be connected to a component of the piping system, such as the stein
46 of the valve 20 or the third pipe 50. As illustrated in FIG. 19,
the framework 450 may include a plurality of ribs which extend
radially outwardly from the component, such as stem 46, a
predetermined distance. The housing 402 is wrapped around the
framework 450 to form the pocket 404. The framework 450 may be
eliminated.
[0121] In an alternative embodiment of the leak sensor assemblies
100, 200, 300, 400, a fan and/or pump 80, see FIG. 23, could be
provided in the housings 102, 202, 302, 402. If a fan is provided,
the fan may be at a position generally opposite the sensor(s) 64,
such that the fan would blow/direct any leaked gases within the
pockets 104, 204, 304, 404 toward the sensors 64, thereby aiding in
ensuring that the sensors 64 would be able to detect the presence
and concentration level of the leaked gas. If a pump is provided,
the pump would suck/direct any leaked gases within the pockets 104,
204, 304, 404 toward the sensors 64, thereby aiding in ensuring
that the sensors 64 would be able to detect the presence and
concentration level of the leaked gas.
[0122] In yet another alternative embodiment, the leak sensor
assemblies 100, 200, 300, 400 could be provided with a
hydrophobic/gas permeable filler 82 in one or more portions of the
pockets 104, 204, 304, 404. For instance, as illustrated in FIG.
24, which generally depicts the leak sensor assembly 100, the
filler 82 is provided in the pocket 104 at or proximate to the
first end 116 of the housing 102. The provision of the filler 82
thus minimizes the effect of wind in the pocket 104 which could
affect the ability of the sensor 64 to properly sense/detect the
presence of a VOC therein. One or more fillers 82 could be provided
in the pockets 104, 204, 304, 404, and the thickness of the fillers
82 can be varied/optimized. The filler 82 may further completely or
substantially fill the pockets 104, 204, 304, 404. As the filler 82
is water/gas permeable, it should not interfere with the operation
of the sensors 64 and/or the overall effectiveness of the leak
sensor assemblies 100, 200, 300, 400. The filler 82 may also have
the advantage of providing further stability in positioning of the
housing 102, 202, 302, 402 relative to the component, thus better
ensuring that the desired volume of the pockets 104, 204, 304, 404
is maintained.
[0123] The reasons for providing the housing 102, 202, 302, 402
with openings 116, 118, 240, 242, 244, 246, 340, 342, 344, 416, 418
thereof are threefold. First, upon a leak of VOCs occurring at the
valve 20/connector 22, 22', the VOCs are provided in the pocket
104, 204, 304, 404. However, as it is not desirable for the
concentration of the VOCs to build-up in the pocket 104, 204, 304,
404, the openings 116, 118, 240, 242, 244, 246, 340, 342, 344, 416,
418 provide outlets which reduce VOC accumulation. Second, the
openings 116, 118, 240, 242, 244, 246, 340, 342, 344, 416, 418
allow for any moisture formed in the pocket 104, 204, 304, 404 to
be drained therefrom. In this regard, the sizes of the openings
116, 118, 240, 242, 244, 246, 340, 342, 344, 416, 418 should be
optimized to minimize the effect of weather conditions on sensor 64
reading while ensuring no moisture build-up inside the housing 102,
202, 302, 402. If desired, one or both of the openings 116, 118,
240, 242, 244, 246, 340, 342, 344, 416, 418 could be closed off, so
long as the closing off of these openings 116, 118, 240, 242, 244,
246, 340, 342, 344, 416, 418 does not have any negative effects on
the operation of the sensor 64 and/or the safety of the process
plant. Also, if desired, the openings 116, 118, 240, 242, 244, 246,
340, 342, 344, 416, 418 may be sealed with the stem 46/body 32/body
52, 52'/pipes 28, 30, 50 and the openings 116, 118, 240, 242, 244,
246, 340, 342, 344, 416, 418 could be provided as one or more
apertures through the housing 102, 202, 302, 402 from the inner
wall surface to the outer wall surface. It should also be
understood that as the fabric forming the walls 306, 406 of the
housings 302, 402 is preferably a microporous fabric, the
microporous fabric would have a multitude of microscopic openings
that would act as drain openings for preventing the build-up of
VOCs and/or moisture within the housings 302, 402. Third, the
housings 102, 202, 302, 402 will act to reduce any bulk water
and/or bulk air flow (e.g., wind) from entering the pockets 104,
204, 304, 404 and disrupting the operation of the sensor 64.
[0124] In any of the embodiments, at least one drain opening 855 is
preferably provided in the housing 102, 202, 302, 402 and is
preferably provided in a position which is closest or substantially
closest to the ground, but which is away from the openings 116,
118, 240, 242, 244, 246, 340, 342, 344, 416, 418. That is, the one
or more drain openings 855 is provided along a lower portion of the
housing 102, 202, 302, 402 as this is the position which is closest
or substantially closest to the ground. The one or more drain
openings 855 is in fluid communication with the pocket 102, 202,
302, 402. The position of the one or more drain openings 855 will
vary depending upon the orientation of the housing 102, 202, 302,
402. For example, when the leak sensor assembly 100 is in the
position shown in FIG. 25, the one or more drain openings 855 is
preferably provided in the wall 102 and may be proximate the second
end 110 of the wall 106. For example, when the leak sensor assembly
200 is in the position shown in FIG. 26, the one or more drain
openings 855 is preferably provided in the base wall 228 of the
housing 202. For example, when the leak sensor assembly 300 is in
the position shown in FIG. 27, the one or more drain openings 855
is preferably provided in the wall 306 underneath the connection to
the pipes 28, 30. For example, when the leak sensor assembly 400 is
in the position shown in FIG. 28, the one or more drain openings
855 is preferably provided in the wall 406 proximate to the second
end and above the pipes 28, 30. The one or more drain openings 855
aids/assists in allowing any moisture in the pocket 104, 204, 304,
404 to exit the pocket 104, 204, 304, 404.
[0125] In some embodiments, the sensor 64 is permanently mounted to
the housing 102, 202, 302, 402 with the sensor 64 is in fluid
communication with the pocket 104, 204, 304, 404 formed by the
housing 102, 202, 302, 402. By permanently mounted, this means that
the sensor 64 is not readily removable from the housing 102, 202,
302, 402. In an embodiment, the sensor 64 is permanently attached
to the housing 102, 202, 302, 402 by suitable means, such as
adhesives, etc.
[0126] In an embodiment, the sensor 64 is removably mounted to the
housing 102, 202, 302, 402 by a collar assembly 955 which forms
part of the housing 102, 202, 302, 402 and provides part of the
pocket 104, 204, 304, 404. The collar assembly 955 allows for the
removable connection of the sensor 64 to the housing 102, 202, 302,
402 such that the sensor 64 can be removed to be repaired/replaced
as desired. An example of the collar assembly 955 is shown in FIGS.
29-33 as assembled to the third embodiment of the housing 302.
[0127] In an embodiment, the sensor 64 includes a body 72 in which
a sensing element is provided. The body 72 of the sensor 64 has a
first part 74 of an interengaging assembly provided thereon, as
best shown in FIG. 32. In an embodiment, the first part 74 of the
interengaging assembly is formed by at least two locking ears 76
provided on the body 72 of the sensor 64. In an embodiment, the
locking ears 76 extend outwardly from an end of the body 72 such
that a space is provided between the locking ears 76 and the end of
the body 72.
[0128] The collar assembly 955 includes an inner collar 956 and an
outer collar 958 which has a portion 303 of the wall 306 of the
housing 302 surrounding the sensor opening 326 sandwiched
therebetween.
[0129] In an embodiment, the inner collar 956 is formed from a wall
962 having a central aperture 964 therethrough which forms the
sensor opening 326. The inner collar 956 may have a base wall 966
and a skirt 968 which extends outwardly from the base wall 966 such
that a recess 970 is formed by the inner collar 956.
[0130] The outer collar 958 is formed of a wall 972 having a
central aperture 978 therethrough. The wall 972 of the outer collar
958 has a second, mating part 980 of the interengaging assembly
provided thereon. In an embodiment, the second, mating part 980 is
formed by at least two recesses 982 provided on the outer collar
958. As best shown in FIG. 33, in an embodiment, each recess 982
has an opening 984 at an end of the wall 972, a planar section 986
extending from the opening 984 to a ramped section 988, and a
planar seat section 990 extending from the ramped section 988 which
is aligned or generally aligned with the planar section 986.
[0131] The outer collar 958 seats within the recess 970 of the
inner collar 956 and the portion 303 of the wall 306 of the housing
302 is trapped between the ring walls 962, 972 of the inner and
outer collars 956, 958. The inner and outer collars 956, 958 are
suitably attached to each other in a known manner, such as by
fasteners which extend through the inner and outer collars 956, 958
and the housing 302.
[0132] The sensor 64 is removably mounted to the housing 302/955.
To attach the sensor 64 to the housing 302/955, the locking ears 76
are inserted into the openings 984 of the recesses 982 until the
locking ears 76 move past the planar sections 986 and the wall
forming the planar sections 986 are aligned with the space between
the locking ears 76 and the end of the sensor body 72. Thereafter,
the sensor 64 is twisted relative to the housing 302/955. The
locking ears 76 slide along the planar sections 986 and then along
the ramped sections 988. The locking ears 76 seats within the
planar seat sections 990 such that the wall forming the recesses
982 is trapped between the locking ears 76 and the end of the
sensor body 72. This prevents the accidental disengagement of the
sensor 64 from the housing 302/955. To detach the sensor 64 from
the housing 302/955, the sensor 64 is twisted relative to the
housing 302/955 in the opposite direction until the locking ears 76
are released from the recesses 982. In an alternate embodiment, the
locking ears 76 are provided on the housing 302/955 and the
recesses 982 are provided on the sensor 64.
[0133] In alternative embodiments of the leak sensor assemblies
100, 200, 300, 400, the leak sensor assemblies 100, 200, 300, 400
could be provided with a plurality of sensors 64 rather than a
single sensor 64.
[0134] While the pockets 104, 204, 304, 404 appear in the figures
to define a substantial volume, the housing 102, 202, 302, 404 may
closely conform to the components of the piping system such that a
minimal volume is provided by the pockets 104, 204, 304, 404.
[0135] Attention is directed to FIGS. 34-40 and the fifth
embodiment of the leak sensor assembly 500 of the present
disclosure. While this embodiment is shown with the first portion
26a of the piping system shown in FIGS. 2A and 2B, this fifth
embodiment can be used with the second or third portions 26b, 26c
of the piping system shown in FIGS. 3A, 3B and 4.
[0136] The housing 502 is formed from a wall 506 having first and
second ends 508, 510 and a securement 592 attached to the first end
508 of the wall 506. The pocket 504 extends from the first end 508
to a sensor opening 526 at the second end 510. The sensor opening
526 is in fluid communication with the pocket 504. The sensor 64 is
positioned and held in place within the sensor opening 526 of the
housing 502 such that the sensor 64 is configured to detect VOCs
within the pocket 504. The sensor 64 shown in FIG. 32 is used with
the housing 502 and the specifics are not repeated herein. In some
embodiments, the wall 506 is formed as a ring.
[0137] In an embodiment, the wall 506 is formed of a rigid
material, such as metal, ceramic, thermoplastic (acrylonitrile
butadiene styrene (ABS), Noryl, polyethylene, polypropylene,
polyvinyl chloride (PVC), polycarbonate, etc.), and particularly
high temperature plastics such as liquid crystal polymer (LCP),
syndiotactic polystyrene (SPS), polyvinylidene fluoride (PVDF),
nylon, and durable high-performance polyimide-based plastics, such
as those sold under the registered trademark VESPEL. The material
of the wall 506 is also preferably water-proof, weather-proof
(e.g., resistant to the formation of cracks, deformation, etc. upon
prolonged exposure to the elements), and chemically resistant to
organic compounds. The material of the housing 502 can further
desirably withstand a wide temperature range, for example,
-40.degree. Celsius to 200.degree. Celsius.
[0138] The wall 506 of the housing 502 has a second, mating part
580 of the interengaging assembly provided thereon. In an
embodiment, the second, mating part 580 is formed by at least two
recesses 582 provided on the housing 502. As best shown in FIG. 36
and 37, in an embodiment, each recess 582 has an opening 584 at the
second end 510 of the wall 506, a planar section 586 extending from
the opening 584 to a ramped section 588, and a planar seat section
590 extending from the ramped section 588 which is aligned or
generally aligned with the planar section 586.
[0139] The sensor 64 is removably mounted to the housing 502. To
attach the sensor 64 to the housing 502, the locking ears 76 are
inserted into the openings 584 of the recesses 582 until the
locking ears 76 move past the planar sections 586 and the wall
forming the planar sections 586 are aligned with the space between
the locking ears 76 and the end of the sensor body 72. Thereafter,
the sensor 64 is twisted relative to the housing 502. The locking
ears 76 slide along the planar sections 586 and then along the
ramped sections 588. The locking ears 76 seats within the planar
seat sections 590 such that the wall forming the recesses 582 is
trapped between the locking ears 76 and the end of the sensor body
72. This prevents the accidental disengagement of the sensor 64
from the housing 502. To detach the sensor 64 from the housing 502,
the sensor 64 is twisted relative to the housing 502 in the
opposite direction until the locking ears 76 are released from the
recesses 582. In an alternate embodiment, the locking ears 76 are
provided on the housing 502 and the recesses 582 are provided on
the sensor 64.
[0140] In an embodiment as shown in FIG. 34-38, the securement 592
is formed by one or more magnets 594 which are mounted on the wall
506. In an embodiment, a plurality of spaced apart magnets 594 are
mounted on the wall 506. In an embodiment, a single magnet 594
extends continuously around the wall 506. In an embodiment, the
magnet(s) 594 are attached to the wall 506 by fasteners 596. The
wall 506 and the attached sensor 64 are magnetically attached by
the magnet(s) 594 to the first, second or third portions 26a, 26b,
26c of the piping system proximate to the components to be
monitored, such as the valve 20 or the connector 22, 22'. This
positions the wall 506 proximate to the components to be monitored,
such as the valve 20 or the connector 22, 22'. The wall 506 and the
attached sensor 64 can be released from attachment to the first,
second or third portions 26a, 26b, 26c of the piping system by
pulling the wall 506, its securement 592 and the attached sensor 64
away from the first, second or third portions 26a, 26b, 26c of the
piping system.
[0141] In an embodiment as shown in FIGS. 39 and 40, the securement
592 is formed by a strap 598 which extends through at least one
opening 599 in the wall 506. The straps 598 and at least one
opening 599 replace the magnets) 594 and fasteners 596.
[0142] In an embodiment as shown, two openings 599 are provided and
the openings 599 are diametrically opposed. The strap 598 extends
through both openings 599 and is wrapped around the first, second
or third portions 26a, 26b, 26c of the piping system. This
positions the wall 506 proximate to the components to be monitored,
such as the valve 20 or the connector 22, 22'. The ends of the
strap 598 can be secured to one another or the free end can be
secured along the length of the strap 598 by suitable means, such
as fasteners, latches, tape, hook-and-loop fasteners (such as those
sold under the registered trademark VELCRO), magnets, snaps,
buttons, etc. The wall 506, its securement 592 and the attached
sensor 64 can be released from attachment to the first, second or
third portions 26a, 26b, 26c of the piping system by disengaging
the strap 598 and pulling the wall 506 and the attached sensor 64
away from the first, second or third portions 26a, 26b, 26c of the
piping system.
[0143] In an embodiment, one opening 599 is provided. One end of
the strap 598 is permanently attached to the wall 506. The strap
598 is wrapped around the first, second or third portions 26a, 26b,
26c of the piping system and through the opening 599. This
positions the wall 506 proximate to the components to be monitored,
such as the valve 20 or the connector 22, 22'. The free end can be
secured along the length of the strap 598 by suitable means, such
as fasteners, latches, tape, hook-and-loop fasteners (such as those
sold under the registered trademark VELCRO), magnets, snaps,
buttons, etc. The wall 506, its securement 592 and the attached
sensor 64 can be released from attachment to the first, second or
third portions 26a, 26b, 26c of the piping system by disengaging
the strap 598 and pulling the wall 506 and the attached sensor 64
away from the first, second or third portions 26a, 26b, 26c of the
piping system.
[0144] While the sensor 64 has been shown and described as being
removably mounted to the housing 502, in some embodiments, the
sensor 64 is permanently mounted to the housing 502 with the sensor
64 in fluid communication with the pocket 504 formed by the housing
502. By permanently mounted, this means that the sensor 64 is not
readily removable from the housing 502. In an embodiment, the
sensor 64 is permanently attached to the housing 502 by suitable
means, such as adhesives, etc.
[0145] In an embodiment, the securement 592 could be provided by a
combination of the strap 598 and the magnet(s) 594.
[0146] Attention is directed to FIG. 41 and the sixth embodiment of
the leak sensor assembly 600 of the present disclosure. While FIG.
41 does not show any of the portions 26a, 26b, 26c of the piping
system shown in FIGS. 2A-4, this sixth embodiment can be used with
the any of the portions 26a, 26b, 26c of the piping system.
[0147] As shown in FIG. 41, in an embodiment, the leak sensor
assembly 600 includes the leak sensor assembly 500 and a secondary
housing 1003. The leak sensor assembly 500 is attached to the
secondary housing 1003 which generally surrounds/surrounds the
portion 26a, 26b, 26c of the piping system (not shown in FIG. 41
for clarity). The secondary housing 1003 may take the form of any
of the housings 102, 202, 302, 402 and forms a secondary pocket
1005 which is in fluid communication with the pocket 504. The leak
sensor assembly 500 is attached to the portion 26a, 26b, 26c of the
piping system and then the secondary housing 1003 is mounted around
the portion 26a, 26b, 26c of the piping system and the secondary
housing 1003 is attached to the wall 506 by suitable means, such as
adhesive. As shown in FIG. 41, the secondary housing 1003 is in the
form of housing 302. In this embodiment of the leak sensor assembly
600, the leak sensor assembly 500 is attached to the portion 26a,
26b, 26c of the piping system by the securement 592 (while the
securement 592 of FIGS. 34-38 is shown in FIG. 41, it is to be
understood that the securement 592 of FIGS. 39 and 40, or a
combination of the securements 592 of FIGS. 34-38 and FIGS. 39 and
40 can be used). In an embodiment of the leak sensor assembly 600
when the secondary housing 1003 takes the form of housing 302, the
leak sensor assembly 500 is attached to the portion 26a, 26b, 26c
of the piping system and then the secondary housing 1003 is wrapped
around the portion 26a, 26b, 26c of the piping system and the
secondary housing 1003 is attached to the wall 506 by suitable
means, such as adhesive.
[0148] Attention is directed to FIG. 42 and the seventh embodiment
of the leak sensor assembly 700 of the present disclosure. While
this embodiment is shown with the third portion 26c of the piping
system shown in FIG. 4, this seventh embodiment can be used with
the first or second portions 26a, 26b of the piping system shown in
FIGS. 2A-3B. As shown in FIG. 42, in an embodiment, in the seventh
embodiment of the leak sensor assembly 700, the leak sensor
assembly 500 is attached to the portion 26c of the piping system
and the housing 702 is formed by waterproof, flexible tape which is
wrapped around the third portion 26c of the piping system which
forms the wall 704. When the tape which forms the wall 704 is
wrapped around the piping system, openings 716, 718 are formed
around the pipes 28, 30. When the tape which forms the wall 704 is
wrapped around the leak sensor assembly 700, in an embodiment, the
tape which forms the wall 704 is wrapped around the wall 506 and
forms an opening 703 around the leak sensor assembly 700.
[0149] In each embodiment, the sensor 64 can be provided with power
via hard-wiring to main power or via a battery. If the sensor 64
requires significant power consumption, then hard-wiring to main
power would be preferred. However, when operated on battery power,
the sensor 64 may be turned on to perform a gas measurement
intermittently, such as at a fixed interval, e.g. every month,
every week, every day, every hour, etc. A battery-powered sensor 64
may be provided with or without a solar panel. A non-dispersive
infrared sensor 64, for example, has a start-up time of no more
than 1 minute. This means the sensor 64 only needs to operate less
than 30 minutes each year, assuming the sensor 64 is configured to
take a gas reading once per month. Even with 200 mW power
consumption, one CR2032 lithium battery that has 230 mAh capacity
can easily last over 5 years.
[0150] In each embodiment, since the sensor 64 is attached to the
housing 102, 202, 302, 402, 502, 702 the sensor 64 is not readily
affected by outdoor environmental conditions, such as wind, rain,
and temperature variations. Due to the provision of the housing
102, 202, 302, 402, 502, 702 around the valve 20/connector 22, 22',
leakage of VOCs out of the valve 20/connector 22, 22' is held
within the pocket 104, 204, 304, 404, 504 such that gas
concentration within the pocket 104, 204, 304, 404, 504 becomes
generally uniform/less sensitive to the position of the sensor 64.
As such, the sensor 64 does not need to be positioned at the exact
point where the leak is occurring. Rather, the sensor 64 can be
generally positioned at certain locations where sensor 64 readings
are most consistent no matter where leaks occur and where effect of
the weather is minimal.
[0151] The housing 102, 202, 302, 402, 502, 702 acts both as a
weather jacket, to prevent the valve 20/connector 22, 22' and the
sensor 64 to exposure of the outdoor environmental conditions, thus
avoiding corrosion of the valve 20/connector 22, 22' and flooding
of the sensor 64, and as a gas concentrator, to allow for the
diffusion of gas to be evenly distributed/concentrated within the
pocket 104, 204, 304, 404, 504. The secondary housing 1003 acts
both as a weather jacket, to prevent the valve 20/connector 22, 22'
and the sensor 64 to exposure of the outdoor environmental
conditions, thus avoiding corrosion of the valve 20/connector 22,
22' and flooding of the sensor 64, and as a gas concentrator, to
allow for the diffusion of gas to be evenly
distributed/concentrated within the pocket 504.
[0152] In an embodiment, the control unit 68, see FIG. 5, and/or
the sensor network 70, see FIG. 6, could also be operatively
associated with the handwheels 48 of the valves 20 in order to
automatically/remotely control the valves 20 as desired in view of
the information from the readings of the sensor 64.
[0153] It is to be understood that while the leak sensor assemblies
100, 200, 300, 400, 500, 600, 700 have been described and
illustrated for use in connection with detecting leaks at valves 20
and at connectors 22, 22', that the same principles could also be
applied at other components of the piping system, for example,
pumps, sampling connections, compressors, pressure-relief devices,
and open-ended lines.
[0154] While particular embodiments are illustrated in and
described with respect to the drawings, it is envisioned that those
skilled in the art may devise various modifications without
departing from the spirit and scope of the appended claims. It will
therefore be appreciated that the scope of the disclosure and the
appended claims is not limited to the specific embodiments
illustrated in and discussed with respect to the drawings and that
modifications and other embodiments are intended to be included
within the scope of the disclosure and appended drawings. Moreover,
although the foregoing descriptions and the associated drawings
describe example embodiments in the context of certain example
combinations of elements and/or functions, it should be appreciated
that different combinations of elements and/or functions may be
provided by alternative embodiments without departing from the
scope of the disclosure and the appended claims.
* * * * *